Liquid/liquid extraction of hydrocarbons in bulk storage tanks

ABSTRACT

Described herein are methods and systems for performing liquid-liquid extraction in bulk tankage. According to certain embodiments, the liquid-liquid extraction can occur in a bulk tank via a circulation loop, in which a solvent mixture is injected with the hydrocarbon ahead of mix valves on the circulation loop. According to other embodiments, a misting system is installed in the vapor or head space of bulk tankage. The misting system distributes small micro-drops of a solvent mixture so as to cause a uniform lay down over the entire top surface area of hydrocarbon. The solvent mixture migrates from the top surface of the hydrocarbon to the bottom of the bulk tank, reacting during migration to cause liquid-liquid extraction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims priority to U.S.Provisional Patent Application No. 62/979,778, filed on Feb. 21, 2020.The aforementioned application is hereby incorporated by reference inits entirety.

FIELD OF THE INVENTION

Described herein are embodiments of liquid-liquid extraction processesfor use with hydrocarbons in bulk storage tanks, and embodiments ofsystems to perform such processes.

BACKGROUND OF THE INVENTION

Liquid-liquid extraction is a separation process for isolating theconstituents of a liquid mixture. The process involves extracting asolute from a solution by bringing it into contact with a secondimmiscible solvent in which the solute is soluble. It is, generallyspeaking, an established process, and together with distillation, thetwo processes are regularly practiced industrial separation procedures.Whereas distillation causes separation by utilizing the differingvolatilities of the components of a mixture, liquid-liquid extractioncauses separation by using a particular solvent (or mixture of solvents)to partition immiscible components.

The petroleum industry utilizes liquid-liquid extraction to separate,for example, different types of hydrocarbons using solvents such asliquified sulfur dioxide, furfural and diethylene glycol. In general,extraction is applied when the materials to be extracted areheat-sensitive or nonvolatile and when distillation would beinappropriate because components have similar boiling points, have poorrelative volatilities, or form azeotropes.

One example of a simple extraction operation is single-contact batchextraction, in which the initial feed solution is agitated with asuitable solvent, allowed to separate into two phases, and then thesolvent containing the extracted solute is decanted. On an industrialscale, the extraction operation typically involves more than oneextraction stage and is normally carried out on a continuous basis. Theequipment may be comprised of either discrete mixers and settlers orsome form of column contactor in which the feed and solvent phases flowcounter-currently by virtue of the density difference between thephases. Final settling or phase separation is achieved under gravity atone end of the column by allowing an adequate settling volume forcomplete phase separation. Such extraction operations are most typicallyperformed in process units, with the hydrocarbon moving through theunit. There is a void in industry for performing liquid-liquidextraction on static hydrocarbons that are stored in bulk tankage.

Naphthenic Acid has been a nemesis throughout the refining process foryears. Typically, the majority of acids present in a hydrocarbon feedare naphthenic acids (a subset of carboxylic acids). They generally havehigh total acid numbers (“TAN”) and are oil soluble. Thesecharacteristics cause various problems in the refining process.

At a crude distillation unit, for example, caustic washes that reactwith naphthenic acids convert the carboxylic acids into naphthenates,which can create severe emulsions in the desalting units. Such emulsionscan greatly decrease desalting efficiency and often minimize throughputto the entire distillation unit. This leaves refiners with a choice oftwo undesirables: do not run high naphthenic acid crudes at all orminimize the relative percentage of high naphthenic acid crudes in theoverall blend. These would be the options in order for the desaltingunits to maintain efficiency. Crude oil itself (not high naphthenic acidcrudes) typically has naphthenates existing in its composition, mostcommonly in the form of calcium naphthenates or sodium naphthenates—theymay exist in the structure of iron, copper, and magnesium as well.

The majority of naphthenic acids typically reside in the heavier cuts ofcrude—because the majority of naphthenic acids are a heavier molarweight, they tend to end up in the bottom cuts of the crude.Accordingly, refiners may struggle with elevated corrosion in the bottomportions of their atmospheric columns and vacuum columns (typicallywhere the heavier cuts reside) due to naphthenic acid finding its way tothose portions of such columns and processing units. These problems canbe exacerbated in systems that lack suitable caustic washing processes.Refiners must also limit their blend of crude feedstocks in order tominimize TAN in heavy fuels that would trigger a discount to the salesprice (fuel must be blended to meet the upper threshold of a maximum 2.5TAN).

By extracting the naphthenic acid in bulk tankage according to theinventive embodiments described herein, refiners can remove or lower theTAN of the virgin crude initially, before it is refined, which minimizes(or even eliminates) downstream processing and the above-statedproblems. Implementing the systems and methods described herein,refiners can extract naphthenic acid and lower TAN from heavy fuel cutsin product tanks, which is can eliminate the excess TAN discount theyotherwise would be forced to take. There is a void in industry forremoving naphthenates and naphthenic acid from static hydrocarbon storedin bulk tankage, before downstream processing and without traditionalrefinery operations.

Sulfur is another nemesis for refineries. Sulfur specifications for allfuels are continually tightening, requiring further removal of sulfur inorder for refiners' products to meet global governmental requirements.The traditional technology for sulfur removal is a hydrotreater, amechanism configured to perform hydrotreating, or the reaction oforganic compounds in the presence of high pressure hydrogen to removeoxygen and other heteroatoms, like sulfur. They are expensive units tobuild and operate, requiring not only the hydrotreater itself for sulfurremoval, but also a hydrogen plant and downstream sulfur recovery unit.Hydrotreaters are product specific and are effective on the lighter cutsof oil, such as naphtha, kerosene, diesel, and gas oil, but fairlyineffective on heavier cuts.

Technology for hydrotreating heavier cuts is limited. There is nocurrent technology to remove sulfur from the crude before it is refined.Thus, a refiner's choices for a crude slate are often very limited bythe sulfur content of the crude and their hydrotreater limitations. Inaddition, new international laws have placed lower sulfur limits onheavier fuels, such as bunker fuels. As a result, there is an increasedneed for new sulfur removal technologies. Removing or reducing sulfurfrom the crude initially, would provide refiners a greater selection ofcrudes without overtaxing downstream hydrotreaters.

Some crude slates are known bad actors for desalting. Due to variouscompounds, they are either difficult to desalt in a classic desalter orthey have extreme high levels of water initially that is emulsified.High water levels in crude causes throughput issues for the crude unitand increased downstream corrosion due to desalter inefficiency.Desalters add fresh water to solubilize salts. Even crudes that aredewatered before being refined will take up water again in a desalter.Desalting and dewatering in tankage will resolve throughput andcorrosion issues derived from these types of crudes. There is a need fora mechanism, apparatus, or system to improve desalting—indeed, tocompletely desalt crudes while minimizing water consumption and outfall.

In liquid-liquid extraction, the problem of what to do with theresulting off-spec liquid being used for extraction is always an issue.With amines, they must be stripped with the extracted material removed.Disposal of water or solvent is expensive and can become aninsurmountable issue because of environmental restrictions. Mostrefineries and terminals are already reaching limits on outfall permitsfor quantity and biochemical oxygen demand (“BOD”) and chemical oxygendemand (“COD”). Disposal of any quantity of water or solvent becomes aneconomic hurdle that would render the process not viable.

Asphaltenes are another common type of material that plague refineries.Most crudes have some level of measurable asphaltenes (the percentagethat are insoluble in n-heptane). Asphaltenes are long chained moleculesthat have a polar tail, making them slightly incompatible with the otherconstituents of crude oil. They can cause havoc from production,transport, storage, and refining because of their capacity toflocculate. Asphaltenes are highly viscous and rich in sulfur, metals(in particular vanadium and nickel, complexed metals with littlecapacity to form salts) and nitrogen. Due to their polar tails, theycause emulsion issues at desalters, as they migrate to the water/oilinterface and accumulate, resulting in oil undercarry and waterovercarry into the crude unit heaters and main fractionator. Asphaltenesare a main source of fouling in crude preheat and vacuum units due totheir tendency to create depositions within the exchangers.

Currently, refinery de-asphalting processes take place on residuestreams, but the material in the streams must go through the crudepre-heat, desalters, a main fractionation unit, and a vacuum unit beforeit arrives at a location where de-asphalting can effectively occur. Thisallows the asphaltenes to cause operational issues on said units, aswell as other downstream units. Regarding downstream units, asphaltenescan migrate up the tower into higher cuts, affecting such downstreamunits and the catalyst—the catalyst, in particular, being sensitive tonitrogen and metal. Further, asphaltenes tend to be rich in phenols,naphthalenes, and other defined polycyclic aromatic hydrocarbons (PAHs).Such materials are well known health hazards, as they have polarconstituents that are water soluble and can leach into the water table.After vacuum residue goes through a de-asphalting unit, it undergoes anair-blowing operation to oxidize the asphalt. One of the primary reasonsfor doing so is to minimize the PAHs before the asphalt can be marketedfor commercial purposes. Air blowing of asphalt is a major source ofgreenhouse gas emissions..

Until now, there has been limited technology to extract undesirablematerials, such as naphthenic acid, asphaltenes, metals, hydrogensulfide, and mercaptans, from hydrocarbon in bulk tankage. The industryis therefore lacking and desirous of systems and methods for strippingthese materials from hydrocarbon (e.g., crude stock) before or duringtransit to a refinery and downstream processing plants, or upon arrivingat a processing site, without having to use traditional distillationmethods.

SUMMARY OF THE INVENTION

Embodiments described herein are directed to methods of performingliquid-liquid extraction in bulk tankage, and systems to facilitate thesame. Embodiments of the present invention are designed to treathydrocarbon in bulk tankage (e.g., storage tanks) while the hydrocarbonis statically contained in the bulk tankage (e.g., at the hydrocarbonextraction site, in transit between extraction and refineries ordownstream processing sites, or at a refinery but before undergoingtraditional refinery processing operations). Treatment of thehydrocarbon in the bulk tankage typically occurs in batch processes. Asdescribed in more detail below, in certain embodiments, circulationloops are on, attached to, or otherwise incorporated with the tankage.These circulation loops are configured to insert/inject solvent mixturescomprising, e.g., one or more alcohol(s), water, glycerin andpotentially other materials. The solvent mixtures react with thehydrocarbon to extract an array of undesirable materials from thehydrocarbon, including naphthenic acid, asphaltenes, phenols, hydrogen,oxygen, nitrogen, hydrogen sulfide and mercaptans, chlorides, sulfur,and water soluble salts and/or metals as well as complexed metals suchas vanadium and nickel. After being injected in the bulk storage tankand reacting with the hydrocarbon, the solvent eventually is decantedand “drops out,” at which point it can be pumped out of the bulk storagetank to a solvent recovery tank. There, the solvent is acidized and thencycled through external reverse osmosis systems to remove metals andsoluble salts to allow clean solvent to be recycled and reused.

According to one embodiment, liquid-liquid extraction can occur via acirculation loop in which a solvent mixture (e.g., comprising water,alcohol(s), and/or glycerin/glycerol) dosed or combined with caustic isinjected with the hydrocarbon ahead of mix valves on the circulationloop. The solvent mixture may be infused with the hydrocarbon input toform a single input stream or injected independently and simultaneouslywith the hydrocarbon. Additionally, a sparging system may be installedin the bottom of the tank comprising vortexing nozzles. Thus, in certainembodiments, the circulation loop is located on or integrated with thebulk storage tank (a processing tank in the sense the liquid-liquidextraction is carried out in said tank). Solvent mixtures may beinserted/injected into the crude via the circulation loop and spargingsystem to allow for contact between the solvent and hydrocarbon. In someembodiments, heat is used in the process. To facilitate that, heatexchangers may be installed on the circulation loop or heaters may beinstalled in the bottom of the tank to supply necessary heat. Anembodiment may also include an elevated high draw, which will cause thehydrocarbon to be exposed to the solvent mixture more quickly. Whilesystems and methods described herein may refer to the storage andprocessing of crude oil, it should be understood that the embodiments ofthe present invention are effective with all types of hydrocarbon (e.g.,all types of crude, vehicle fuels, lubricating oils, bunker oils etc.).

According to another embodiment, a misting system is installed in thevapor space or head space of the bulk tankage. The misting systemcreates small micron drops of a solvent mixture that “lay down” over theentire top surface area of the hydrocarbon and migrates through thehydrocarbon, reacting as it falls to the bottom of the tank where it ispumped off from the sump.

In order to facilitate liquid-liquid extraction in fuel oil orhydrocarbons with an extremely low American Petroleum Institute (“API”)gravity, one embodiment comprises a sparging system that can utilizesteam along with the solvent that has a higher vapor point. Althoughmost chemistries added to the steam in accordance with this inventionhave a vapor point higher than 212° F., the steam provides adistribution system as well as the water source to combine with thesolvent for the extraction to occur. The steam and solvent mixturecondenses once it is injected into the tank and rises to the top, wherehigh draws allow for the water and solvent to be removed.

Embodiments of the systems described herein have been found to beparticularly effective for liquid-liquid extraction of: (1) naphthenicacid from hydrocarbon; (2) sulfur from hydrocarbon; and (3) watersoluble salts or metals (4) asphaltenes and the constituents that areheavily enriched in said asphaltenes. And, according to certainembodiments, once acid, sulfur, asphaltenes, and salts are removed,extracted naphthenates can be converted back to naphthenic acid forsale, extracted sulfur can be resold, extracted asphaltenes can bemarketed to various commercial outlets and extracted flocculate saltsmay be properly disposed. Moreover, the water/solvent mixture used forliquid-liquid extraction can be re-used within the process. Certainother embodiments utilize ultrasonic sound waves, either initially, orthroughout the extraction process. Doing so excites molecules, which canexpedite reactions.

According to another embodiment of the present invention, a method ofliquid-liquid extraction comprises several steps. In the first step, itis important to understand the compositional makeup of the mixture. Itis advisable to check for certain physical properties, such as APIgravity, total metals (with particular attention to metals that have thepotential to become salts or metal soaps, such as sodium, calcium,magnesium, potassium, iron), total acid number (“TAN”), percent (%)asphaltenes, and viscosity. This initial step further comprisesdetermining and measuring the total volume of hydrocarbon coming intothe system or bulk tankage. In certain embodiments, an additionalinitial acid/solvent washing step may be performed to convert metalnaphthenates into naphthenic acid in order to allow the metals to dropout with the solvent. This step may be useful, for example, when metallevels (e.g., calcium levels) are extremely high.

The second step of this exemplary embodiment is to calculate the dosageof caustic chemistry (e.g., potassium hydroxide (KOH) or sodiumhydroxide (NaOH) solution) to be dosed/injected into the solvent for thesolvent washing step. Using KOH or NaOH, dose the caustic at 1,000 ppmper every point of total acid. As KOH is slightly weaker, it can requirea stronger dose than if utilizing NaOH. A simple lab dosage ofhydrocarbon being stirred with the caustic and a check of total acidwill confirm proper dosage amount. For example: A TAN of 5.0 wouldrequire a dosage of 5,000 ppm of caustic.

The third step of this exemplary embodiment is to combine caustic-dosedsolvent and hydrocarbon. The use of caustic to neutralize acids (whichare most likely naphthenic acids) will form metal soaps, which tend tocreate severe emulsions. Water alone is not effective in extractingacids without also extracting hydrocarbon. Rinsing the oil with asolvent of water and alcohols allows for the extraction of metal soapwithout extracting hydrocarbon other than hydrocarbons specificallytargeted such as asphaltenes or PAHs that are also targeted due to theirpolarity issues. Many alcohols are effective. For example, a solventrecipe may comprise 30-50% alcohol(s), 20-40% water, 20-40%glycerin/glycerol may be used (% by weight), where one useful solventmixture comprises 40 wt.-% ethanol, 30 wt.-% water, and 30 wt.-%glycerin/glycerol. Ethanol provides for a cleaner, more efficientextraction of soaps, as compared to water and glycerin alone.Glycerin/glycerol in the solvent combination is useful in order toprovide a solvent gravity that is heavy and desires to drop out of thehydrocarbon in tankage.

Generally, the solvent-to-oil ratio may be 10:50 by mass, oralternatively 20:40 by mass. In certain embodiments, the solvent can beblended with the hydrocarbon on the run-down from a ship or barge or ona circulation loop after hydrocarbon is in the tank. In certainembodiments, the caustic can be injected neat into the crude orpre-dosed into the solvent. Pre-dosing caustic into the solvent mayprovide benefits of better distribution and contact.

In this step, according to certain embodiments, the solvent,hydrocarbon, and caustic are circulated together for at least 6 hours,advantageously at least 12 hours up to and including 24 hours, to allowfor full contact of acids and caustic. It may be useful to periodicallycheck the TAN of the solvent/hydrocarbon mixture to determine if fullreaction has taken place. For a full reaction, the TAN will benon-detectable or a minimal value. Reaction and separation happenregardless of temperature and can be performed at ambient conditions.Notwithstanding this, circulation can also occur under elevated heatedconditions. Slight amounts of heat (no more than 150° F., due to boilingpoints of alcohols, for example) can facilitate more efficient blendingand separation because elevated temperatures lower the viscosity of thehydrocarbon. After enough contact has taken place, circulation stops andthe tank is allowed to become sedentary.

At this point in the process, the solvent will immediately begin to dropand separate from the hydrocarbon. Once approximately 30% of the solventhas separated, the solvent/metal soap can begin to be pumped off totreatment skids (or treatment tanks). It is expected that total solventdrop out will take approximately 24 hours. The metal soap contentexpected to be recovered is approximately 0.1% to 15.0% of crude volumeper point of TAN. In addition, if original metals (e.g., sodium orcalcium) are present in excessive quantities, then it may be assumedthat there was a pre-existing metal soap present, which will increasevolume per the ppm reported. After solvent has been removed, totalmetals, pH of oil and water, percent (%) asphaltenes and TAN should berechecked.

The fourth step in this exemplary embodiment is an optimization step anddepends on one's ultimate goal. For instance, one process goal may be tocompletely remove soap or ultimate resulting naphthenic acids orasphaltenes. In that scenario, evaluating the level of total metals or %asphaltenes after solvent rinse will indicate how much of the metalsoaps or asphaltenes were not picked up and extracted in first rinse.Generally, a sodium, potassium, or calcium number would be in the 100 to300 ppm range. If the optimization goal is to completely remove soap oradditional removal of soap and asphaltenes, then one or more additionalsolvent rinses may be required. The pH of oil will be high, but mostlikely not high enough for the soap to be in the range that the soapwill cause an emulsion.

According to an embodiment, to remove soap entirely, an additionalsolvent rinse comprises dosing the solvent with a small amount ofcaustic, enough to merely to bring the solvent pH above 11 so as toprevent the soap from forming a lather. Then, the procedure forcontacting and settling of the solvent is repeated. The first passresults in the majority of both soaps as well as asphaltenes beingextracted, however, every subsequent pass will result in a smaller levelextracted until both quantities become trace levels.

In an alternative embodiment, where the optimization goal is to extractthe metals from the solvent after the liquid-liquid extraction reactionwith the hydrocarbon, a solvent wash with acid will be required in asolvent recovery unit, remote from the bulk tankage unit. After theliquid-liquid extraction occurs, the solvent (which now contains theundesirable materials, such as naphthenates and asphaltenes) is decantedand pumped out of the bulk tankage to a solvent recovery unit. There,the solvent is acid washed or acidized with strong acid. Exemplarystrong acids that may be used include HCl or H₂SO₄. The acids break downthe soaps, convert the metal soaps back to a naphthenic acid, and formmetal salts that are solvent soluble.

The addition of acid can improve treatment. For example, recoveredsolvent can be injected with acid on its way to one or more settlingtanks. The acid will immediately begin to convert the naphthenate soapsback into naphthenic acid as well as force the asphaltenes that weresolubilized in the high pH solvent out of solution, which both will riseto the top of the processing tank no longer soluble with the solvent. Itcan take time to separate and fully convert naphthenate soap intonaphthenic acid (at least 5 hours up to as many as 24 hours). Forincreased speed and efficiency, certain embodiments comprise multiplesettling tanks and sheering mixers for closer contact between strongacids and soaps for reaction. The naphthalenes and phenols (PAHs) tendto remain in the solvent as opposed to migrating back with thenaphthenic acids and asphaltenes, as they are readily soluble inalcohol, in particular ethanol. The reverse osmosis then captures themfor recovery for value or BTU recovery at the thermal desorption unitsand removes them from the solvent bound for re-use within the process.

The acid-washed solvent then may be “recycled” through a bank of solventtreatment skids. Such skids may be advanced oxidation skids that, withan electrical charge and specialized catalyst plates, can convert themetal soaps back to naphthenic acid. Such converted naphthenic acid canbe skimmed off, and any metal salts created can be precipitated out.This allows for the solvent recipe to be reused and recycledcontinuously. In other embodiments, solvent recycle may be treated usingreverse osmosis skids comprising carbon filters or organic membranes tocatch any crude or converted naphthenic acid that may have carried over.Reverse osmosis skids are effective for removing salts and chlorides andrepairing solvents for reuse.

In certain embodiments, reverse osmosis (“R/O”) equipment is used inlieu of oxidation skids. R/O skids “cycle up” the concentration ofextracted constituents (e.g., metals, naphthalene, phenols, sulfursalts, and chlorides) in the solvent mixture. The cycled-up material canbe sent directly to a cement kiln for recycling of the metals intocement (e.g., Portland cement). The alcohol and glycerin components ofthe solvent mixture, along with the naphthalenes and phenols, have BTUvalue. In addition, alcohol and glycerin are renewable fuels subject tomonetary rebates when consumed for energy, as well as emissionstradeable credits. Thermal desorption burns will create energy and heatto self-sustain the nominal heat required to provide for the tankageheating options discussed herein.

According to certain embodiments, the extraction process utilizes anadvanced oxidation water treatment facility, which, through oxidationvia catalyst plates, is able to produce a water of potable quality orclean solvent. For example, sodium naphthenate that is extracted fromthe crude from exposing NaOH or KOH to the naphthenic acid is oxidized.That removes the Na, Ca, or other compound(s) that can convert thenaphthenates back to the various molar weights of naphthenic acids. Thisenables continuous recycling for re-use in the liquid-liquid extraction.The advanced oxidation flocculates the material being extracted andrecovers them as a saleable product or a concentrated material for safedisposal at an appropriate facility. The advanced oxidation alsoflocculates out the sulfur that is also extracted. The sulfur that issegregated can be sold into the raw sulfur industry where there is awide variety of industrial uses. In other embodiments, this extractionprocess may, in addition to or in combination with the advancedoxidation equipment, utilize reverse osmosis skids, as mentioned above.

An acid step or acid wash may also be implemented in the oil reactionstage in the bulk tankage. Such embodiments comprise slowly adding acidto the solvent in an amount about or equal to (in ppm) the amount ofmetals remaining in the oil along with any level of basic nitrogen,followed by circulating the acidized solvent and hydrocarbon for about12 to 24 hours. The acidized solvent converts metal soaps to metalsalts, and the metals in the crude will have reduced, or trace, ornominal levels in the crude once solvent drops out. The basic nitrogenlevel of the crude will also drop as a result. A final polishing rinsewith solvent might be necessary with no chemistry (e.g., without furtherdosing caustic or acid) to rinse any strong acids remaining in the oil.The level of strong acids in the crude can be monitored various ways:e.g., by measuring TAN and calculating strong acid levels, or ifutilizing HCl as the strong acid, measuring total chloride level.

The systems and methods described herein may also be incorporated atupstream stages of hydrocarbon processing. The embodiments of thepresent invention described herein may be implemented during hydrocarbontransport (e.g., on a ship or vessel). In transit, circulation loopsystems attached to or incorporated with the hydrocarbon bulk tankagecan allow for initial contacting of solvent mixture and hydrocarbon,even before the hydrocarbon arrives at its destination (e.g., refinery).In this context, if the circulation loop systems are turned off ordisconnected, the solvent mixture will drop out from the bulk tankage,allowing it to be removed and directed to solvent extraction tanks onsite. The hydrocarbon in the bulk tankage will thus be “pre-treated”(e.g., naphthenic acid removed, asphaltenes removed, and water solublesalts or metals removed) all before being directed for furtherprocessing on site (e.g., at the refinery). Upstream stages where theembodiments of the present invention may be implemented include alltypes of transport (e.g., ship/barge or rail).

Furthermore, at the point of crude production or wellheads, specificallyregional crudes that tend to consistently have same issues, this processcan be applied at production to lessen the transport issues that ensueor mitigate the need at the refining location. For example, theembodiments described herein may be advantageous in “pre-treating”crudes that tend to run with high TAN, asphaltene, metals and nitrogen,such as North Sea naphthenic crudes and Canadian bitumen crude. Thedescribed extraction processes could be inserted in lieu of portions ofthe hot water washing methodology currently utilized for recoveringbitumen from the oil sands. This could enable Canadian operations torecover the asphaltenes, naphthenic acids and PAHs at the origin ofproduction for future commercial use, while sending the saturates,aromatics, and resins blended with condensate through varioustransportation methods onward to larger integrated refiners for furthermanufacturing.

Further, the processes described herein as opposed to just hot water aremore effective in stripping the bitumen oil from the sands because of,among other things, the combination of alcohol and water possessing morestripping power. In addition, utilizing water alone leaves some residueof PAHs and naphthenic acids in the waters collected in tailing ponds.The inventive embodiments described herein provide a more completeremoval of PAHs and naphthenic acids.

In certain embodiments, an additional feature is to distill the repairedsolvent once it exits the reverse osmosis units. Bitumen crude containslarge quantities of water that would increase ratio of water to alcoholto glycerol ratio. Recovery of alcohol and water as separate fractionsallows for the recovery of alcohol and some level of water whileoutfalling unwanted yet clean water in order to maintain the correctratios for solvent effectiveness.

Naphthenic acids have multiple uses in the industry, ranging from fueladditives to corrosion inhibitors to main ingredients for paint dryersand lumber treatment. The heavier molar weight naphthenic acids arehighly sought after because they are difficult to extract fromhydrocarbon. Embodiments of the present invention allow for extractionof naphthenic acids from crudes and heavy fuels, ranging in molar weightfrom very heavy to light. The various weight naphthenic acid may be soldto a naphthenic acid refiner who has the capabilities to further refinethe acid into specific molar weight acid. In addition, as the naphthenicacids and asphaltenes are extracted together and must be gentlydistilled to separate, an on-site distillation facility for theseparation of the majority of asphaltenes from lighter naphthenic acidscan be installed or the entire mixture sent onward to consolidationfacilities designed to separate the asphaltenes from acids and furtherupgrade both the naphthenic acids as well as the asphaltenes forcommercial use.

Liquid-liquid extraction embodiments described herein are performed inbulk tankage in batch operation, with minimal amounts of equipment, anda relatively green carbon footprint. These embodiments can also beimplemented in terminals for crude blends being shipped to refiners oron bunker or fuel oil blend-stocks being delivered from refiners. Usingthe embodiments described herein on the back end of the refinery onheavier cuts allows refiners to meet the new sulfur specificationswithout requiring them to develop, invest, and build new hydrotreatertechnology specific for heavy fuel. This also allows for heavy crudes tobe treated in terminals and directed directly to market, bypassingrefineries.

In practice, process engineers have typically separated and treatedcrude hydrocarbon by running (or moving) the hydrocarbon throughrefinery processing units (e.g., distillation columns, separators etc.).The embodiments described herein provide for separation and treatmentwithout moving the crude hydrocarbon; rather, the separation andtreatment can be performed on stationary hydrocarbon in tankage. As aresult, upstream hydrocarbon owners and producers, who may not operate arefinery, have the capability and flexibility to upgrade the value ofthe hydrocarbon they have purchased by addressing numerous problems atonce, such as removing naphthenic acid, metals, and asphaltenes.

The advantages of bulk tank liquid-liquid extraction embodimentsdescribed herein are multiple. For example, the process can be performedoutside of a refinery in a terminal; it can permit treatment of greatervolumes of crude hydrocarbon; and it allows for flexibility on treatmentoptions (e.g., typical process units are limited by location and lineupof the units). Naphthenic acids, moreover, are detrimental to genericrefinery processing units, so it is beneficial to remove naphthenicacids before the crude hydrocarbon enters the refinery. Additionally,the embodiments of the present invention can also more efficientlyde-salt and minimize corrosion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an exemplary system for performing theliquid-liquid extraction in bulk tankage methods described herein.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Embodiments of the system that performs the liquid-liquid extractioncomprise numerous pieces of equipment. Certain pieces of equipment,components, and features of these embodiments are described in moredetail below.

According to certain embodiments, and in general reference to FIG. 1,the system 100 comprises a main bulk processing tank 10 (also referredto herein as bulk storage tank, storage tankage, bulk tank,liquid-liquid extraction unit, or the like) where the liquid-liquidextraction occurs. The size of the tank can range from 1,000 barrels(bbls) up to and including 1,000,000 bbls. Typically, the liquid-liquidextraction of the present invention is performed as a batch process,where the hydrocarbon does not move once it arrives in the bulk storagetank (e.g., from a raw/crude hydrocarbon stream 30), until thecompletion of the process. Liquid-liquid extraction processes describedherein can be performed in any size storage tank that is feasible to bebuilt.

According to certain embodiments the storage/processing tank 10 has thefollowing features. The processing tank 10 may or may not comprise a topenclosure, such as a floating roof, depending on the type of processingperformed in the unit. Generally, the processing tank 10 will notcomprise a floating roof, either internal or external, if the solventmixture is introduced via misting process. This is to allow for a headspace and room for processing equipment associated with a mistingsystem. However, if the solvent mixture is introduced via circulationloop, then the processing tank may comprise a top enclosure, such as afloating roof.

In certain embodiments, an electrical current source is incorporated orattached to the floating roof of the processing tank. The electricalcurrent source may be arranged as a caged grid of electrical probes.Such grid system covers the entire under portion of the floating tank. Aprobe system is equally distributed and connected to the floating roof,and the volume or number of probes in the system are dependent upontheir voltage and amperage distribution. In practical terms, theelectrical current source for the floating roof generally is akin toelectrical current sources used an incorporated in desalter units.Desalter units use electrical current sources to drive out brine waterquickly from incoming crude. The electrical current source heightens thepolarity of the salt laden water and increases the speed of separation.Similarly in the present system, the electrical current sourceincorporated into the floating roof can be used to accentuate,accelerate, and make separation more efficient.

By way of example here, once the solvent mixture has begun to be pumpedoff (after introduction to the hydrocarbon and a few hours hold time),the electrical grid system located at the top of the tank can be placedon a “pulse” system to expedite the separation of the solvent from thehydrocarbon. The electric pulsing will also encourage the extraction ofslightly polar constituents from the hydrocarbon. It promotes a cleanerbreak between hydrocarbon and solvent, while maximizing the extractionof problematic polar constituents.

The processing tank 10 may further comprise a heating system. Theheating system may be installed in the bottom of the tank or verticallyalong one or more sidewalls of the tank, or a combination of both. Theheating system comprises either a hot oil or steam coil system in orderto allow the tank to be heated to temperatures of at least 100° F. up toand including 200° F. (advantageously, the system will heat to atemperature ranging from 130° F. up to and including 160° F., or 140° F.up to and including 150° F.), if desired for adjusting hydrocarbonviscosity and increasing contact efficiency between the hydrocarbon andadditive streams (e.g., solvent mixture). The storage tank may comprisea circulation loop, and heat may also be applied via heat exchangers onthe circulation loop.

The processing tank 10 may further comprise relief valve systems. Therelief valve systems may comprise a system configured to route light endvapors and nitrogen to a light ends recovery tank or straight to thermaldesorption unit for BTU recovery. Such relief valve systems may alsoincorporate or work in conjunction with vapor recovery systems, whichare configured to recondense light end vapors. The inclusion of suchsystem allows for flexibility of taking in low flash hydrocarbons andadding nominal amounts of heat without the loss of the hydrocarbon. Thisvapor recovery system and thermal desorption safely routes any H₂S ormercaptans that reform in the acid phase for reaction into productiveproducts or to the thermal desorption to be utilized for BTU recovery.

The bottom of the processing tank may further comprise a gas spargingsystem (e.g., for nitrogen/air) in order to “nitrogen strip” light endsto the recovery tank, if required. Including this feature allows forflexibility if electing to intake low-flash hydrocarbons. The gassparging system may also be configured to inject steam into theprocessing tank.

The inside of the processing tank 10 may comprise a corrosion controlcoating throughout to minimize corrosion due to extreme pH swings. Ifthe temperature within the tank is kept below 150° F., then both causticand acid corrosion is only nominally invasive to carbon steel. However,certain processing techniques described herein may require highertemperatures, which could increase the possibility for corroding theinside walls of the tank. Using a corrosion control coating couldmitigate this concern.

In certain embodiments, the floor and footings of the processing tank 10are installed and configured to be at a slight angle leading to a deepsump in order to facilitate gathering of the liquid being used forextraction with ease—without pumps also sucking oil. In otherembodiments, a flat floored tank with a small sump can be utilized.

The processing tank 10 may further comprise a high draw for pumping offfinished product to a product tank. Finished product may alternativelybe pumped from sump or low draw. A high draw is advantageous because itcan avoid pumping off any small layer of emulsion at the interface ofoil/liquid being used for extraction.

The processing tank 10 may further comprise a weir installed at thesump. The weir can minimize hydrocarbon vortexing with the solvent whenthe final quantities of solvent are being pumped off.

According to certain embodiments, the system comprises a misting systemconnected to or integrated in or with the storage tank 10. The mistingsystem is configured to evenly distribute the liquid being utilized forextraction (e.g., caustic-dosed solvent mixture) in an even layer acrossand upon the total surface area of the hydrocarbon at the top of thetank. A misting system may be incorporated or installed according tovarious options, described as follows.

In certain embodiments, the misting system may comprise numerous misters(or mister heads) that produce a droplet size of 15 to 50 microns. Themisters are attached to piping emanating from the floor of the tank 10.The piping system is evenly distributed throughout the tank. The pipeslead from a feed system installed in the foundation of the tank, leadingto individual pipes that measure in length so as to extend higher thanthe highest safe fill of the tank in the additional head space allowed.Each pipe ends at a header system, at which the plurality of misters areinstalled. The misters are configured and positioned to point upwards,away from the hydrocarbon contained in the storage tank. In this manner,when misting occurs, it creates a fog that will evenly lay down over theentire surface area of the hydrocarbon. The pipes may be braced at thefloor and footings can be engineered to support the additional weight ofthe piping and liquid being pumped.

In certain embodiments, the misting system is installed in the headspace of the storage tank 10 and braced at the roof with an additionaltruss system to support the weight (the roof itself would not likely beable to support the weight of the misting system itself). According tothis configuration, the misters are configured and positioned to pointdownward toward the hydrocarbon. The misters are further configured tospray in a pattern that completely covers the surface area of thehydrocarbon. The misters would still produce droplets having size withinthe range of 15 up to and including 50 micron. In embodiments in which amisting system is installed in the head space of the processing tank,the tank may comprise an infrared foam indicator in head space as well,like those that may be used in coke drums. Regardless of the mistingsystem's configuration, it may comprise a heat exchange featureconfigured to heat the liquid solvent mixture being introduced to thehydrocarbon. As explained in more detail below, solvent mixture may bepumped from a separate storage unit, and the heat exchange feature canheat the solvent as it travels from the separate storage unit to themisting system. A heated solvent mixture can speed up the reaction withthe hydrocarbon.

In certain embodiments, a sprinkling system substitutes for the mistingsystem. The sprinkling system is installed at the roof with a trusssystem. With a sprinkling system, however, the micron size of the liquiddroplets would be larger than with a misting system. As a result,distribution and surface area contact of solvent mixture ontohydrocarbon may not be as effective with the sprinkler system, ascompared to the mister system.

As mentioned previously, in certain embodiments, the system comprises acirculation loop for distribution and delivery of the solvent/causticmixture. When electing to use a solvent mixture circulation loop, mixvalves and a vortexing nozzle sparging system are advantageously used incombination. The circulation loop may be constructed, installed, andincorporated as a permanent feature or it can be included as a temporaryloop. The temporary loop allows for the injection of solvent ahead ofthe pump (e.g., from solvent tank 20). Pump impellers may beincorporated in the tank to act as a blender. Impellers may be tied backinto a sparging system within the bottom of the tank 10. For a faster,more efficient blending and contacting of the solvent mixture with thehydrocarbon, the system may comprise numerous circulation loops aroundthe diameter of the tank. Incorporating a plurality of circulation loopscan maximize exposure between solvent and hydrocarbon.

Each circulation loop may further comprise additional features andcomponents. For example, as mentioned above, a circulation loop maycomprise a heat exchanger, which is configured to heat the hydrocarbonbefore solvent is injected. Heating the hydrocarbon lowers itsviscosity, which helps to increase contact between solvent andhydrocarbon.

Each circulation loop may comprise mix valves. The mix valves areconfigured to mix solvent mixture and hydrocarbon during transportthrough the circulation loop. Mix valves may be located at one or morelocations along the path of a particular circulation loop. Theprocessing tank may further comprise a vortexing nozzle/sparging systemthat allows for the hydrocarbon to further blend and contact with thehydrocarbon residing in the tank.

In certain embodiments, draws leading to the circulation loop arelocated high on the tank (e.g., above the midpoint of the tank or at alocation in the upper half of the tank). Such configuration allows for amore complete exposure of the hydrocarbon to the solvent mixture withinthe tank, which could mitigate or eliminate the need for the vortexingnozzle/sparging system. Notwithstanding, certain embodiments featurehigh draws to the circulation loop coupled with a vortexingnozzle/sparging system. If locating high draws well above the internalfloating roof legs, check valves should be installed directly next tothe tank in order to minimize back flow of oil into the tank when volumeof the tank has been dropped.

The processing tank 10 may further comprise a piping system for drawingwater and/or solvent mixture from the tank, not only at the sump. Suchpiping system may comprise repeated draws, equidistant from one another(e.g., every 6 inches or every foot), in order to draw water from thetop of the tank, when the tank is in fuel oil treatment service andsolvent is drawn from the top.

As mentioned previously, the processing tank 10 may comprise a spargingsystem at the bottom of the tank with vortexing nozzles. Such spargingsystem provides additional blending of solvent/hydrocarbon intohydrocarbon within the tank. The sparging system may also be utilized toblend the solvent mixture and/or to allow for blending of asteam/solvent mixture.

The processing tank 10 may further comprise a nitrogen purge system forthe head space of tank 10. A nitrogen purge system is generally forsafety purposes if a misting system is included. In certain embodiments,nitrogen is injected into the head space of the tank to keep the vaporspace inert. Accordingly, the nitrogen purge system is a safety featureto clear the head space of gas, if necessary.

According to certain embodiments, the system 100 comprises a solventbulk storage tank 20 dedicated for storage of clean liquid solvent meantfor the liquid-liquid extraction process. The liquid solvent maycomprise water, amines, organic solvents (e.g., acetone or any type ofalcohol such as ethanol or isopropyl alcohol), or combinations thereof,designed to facilitate liquid-liquid extraction. As used herein, theterms solvent and solvent mixture refer to the liquid injected orintroduced into the bulk storage tank, which reacts with the hydrocarbonto extract acids and other undesirable materials from the hydrocarbon.In certain embodiments the solvent may consist of water only; in otherembodiments the solvent mixture may comprise multiple materials,including a plurality of water, amines, organic solvents, and/orglycerin. The solvent bulk storage tank 20 can vary in size depending onthe volume of solvent mixture needed to process the hydrocarbon in theprocessing tank. The solvent storage tank 20 can have an optionalfloating roof if the solvent mixture being used requires vapor control.

The system 100 may further comprise separate storage tanking andinjection systems, as necessary, to account for other liquid componentsthat may be required for the liquid-liquid extraction. For example,water, caustic, acid, and/or peroxides may be useful liquid componentsfor the extraction techniques described here. The system, therefore, maycomprise a plurality of storage tanks, one each for these other liquidcomponents. The system also comprises injection systems corresponding tothese liquid components and integrated and incorporated with theplurality of other storage tanks. The injection systems are configuredto inject liquid components necessary for liquid-liquid extraction intoeither the processing tank directly, the solvent feed line, a mistingsystem feed line, or a circulation loop.

In certain embodiments, the system 100 comprises a light ends recoverytank. In case the process has initial light ends (e.g., naphtha),vaporized light ends and nitrogen are collected at the top of theprocessing tank 100. The light ends vapor is recondensed by a vaporrecovery system and then pumped back into the bottom of the tank. Thelight ends recovery tank comprises a constant water table in order tosolubilize any solvent that may vaporize and keep it separate from thelight ends vapor. The light ends recovery tank also has a relief valvein order to relieve the excess nitrogen to the flare system. Condensinglight ends vapor can also take place in an exchanger, in thealternative.

H₂S and mercaptans in the caustic phase of treatment are bound as asalt. However, in the acid phase of the process, they are re-released asa gas both on the raw crude and any salts that were not fully extractedalong with the extracted material. In certain embodiments, the vaporrecovery system is routed through a thermal desorption unit for initialheat and energy recovery. The thermal desorption units have scrubbersthat minimize ultimate emissions.

The addition of acid to a basic environment is exothermic and springsH₂S and mercaptan gases. Certain embodiments may be capable ofself-heating through this exothermic reaction. In such embodiments, acidis added slowly to allow for a slow reaction and to control theexothermic reaction and to control the production of H₂S and mercaptangases. Correspondingly, nitrogen used in the sparging system creates asmall amount of positive pressure on the tank to continually purge thegases from the tank into the vapor recovery system for incineration andenergy recovery. The thermal desorption system may be lined up with andconnected to the spent solvent system for continuous feed. Regulationmechanisms can adjust the feed flow depending upon the heat needs forthe system, as it varies due to batch operation.

The vapor recovery system may also be connected and integrated with thespent solvent system. The spent solvent tank can have a line up forintroduction of spent glycol, spent caustic, and spent amines which allhave some level of BTU value. According to the processes describedherein, water is picked up from the crude. Any additional materials suchas amines, glycols, or spent caustic will also have additional water.The thermal desorption unit can create steam from this water content.Such steam may be routed to heat exchangers in the bulk tankage heatingsystem in order to recover heat. Once condensed, it can be sent to awastewater treatment plant as relatively clean water for outfall or to amake-up water system for recirculation into a cooling water system orinto the solvent mixture. The thermal desorption unit allows for thesystem to be relatively self-sustaining on energy consumption. Being arenewable system that promotes a high level of water recycling andconservation is an unassailable advantage of the present invention.

In certain embodiments, the system 100 comprises recovery and recyclingsubsystems. Liquid-liquid extraction processes described herein mayproduce spent water. A recovery and recycling subsystem may comprisewater treatment facilities. For example, water treatment facilities mayutilize advanced oxidation units and/or reverse osmosis skids to extractthe majority of solubilized metals, salts, sulfurs etc. in the spentwater. Although not a critical requirement, without a water recyclingsubsystem, the amount of water that would be consumed and that wouldneed to be disposed would be significant and create economicinefficiencies. Other recovery systems for solvents, amines, and otherliquid components used in the liquid-liquid extraction may beincorporated as well.

The components and features described above can be used to performliquid-liquid extraction in bulk tankage, regardless of the size of thetank. FIG. 1 illustrates an exemplary embodiment of the system designedto perform the liquid-liquid extraction methods described herein.

According to an embodiment of the present invention, to extractnaphthenic acid in bulk tankage, naphthenic acid is reacted with NaOH(caustic) or KOH. This reaction converts the various molar weightnaphthenic acid to sodium or potassium naphthenate (soap). The reactionalso creates an emulsion in crudes or heavy fuels that, until now, wasconsidered impossible to remove or break in any type of traditionalprocessing unit. Any type of severe blending, such as the oil passingthrough a pump impeller, would further increase the severity of theemulsion in the presence of water alone.

Naphthenic acid can be completely converted to naphthenate with variousstrength caustic—e.g., full strength, 50% neat, or caustic dosed withina solvent mixture. Caustic can be dosed with solvent mixture on the rundown from the vessel (e.g., raw/crude stream 30) to the storage tank 10with mix valves in line to ensure contact. Dosage will vary dependingupon the incoming TAN. Lab titration may be used to specifically definethe required dosage, but generally, a point of TAN will require 1 mgKOH/kg solvent mixture, approximately 0.1% full strength caustic, toreduce the TAN to non-detect. In certain embodiments, a sparging systeminstalled with a circulation loop can allow for the introduction ofadditional caustic and blending, if the rundown dosage is notsufficient. When using a solvent that is heavily laden with naphthenatesand asphaltenes, the solvent will have a very dark color, almostindiscernible from the color of the oil, except for a prevalent ambertint. As the rinse progresses and the quantity of naphthenates andasphaltenes being extracted are reduced, the color of the solvent willmove to an amber color.

Once the TAN is brought to a non-detect or acceptable level, it is inthe form of naphthenate soap, which will, if exposed to water alone,create a severe emulsion. Because soap is miscible in both oil andwater, any type of agitation will make the emulsion very difficult tobreak. However, water and soap can be displaced or a solvent mixture canminimize the emulsion and allow the naphthenates to easily migrate tothe solvent mixture and extract from the oil. A solvent mixture of waterand alcohols can minimize the emulsion and encourage the naphthenates tomigrate to the solvent from the oil, along with promoting asphaltenes tosolubilize instead of remaining at the oil/water interface.

Water and/or solvent mixture will continuously displace in the bottom ofthe tank. According to certain embodiments, the water and solventmixture is pumped off to a storage tank for naphthenic acid andasphaltene recovery. After naphthenic acid and asphaltenes arerecovered, the solvent proceeds to reverse osmosis water treatmentskids. The reaction between caustic and crude or acid and crudegenerally occurs at ambient temperature; however, in certainembodiments, tanks may be heated with steam coils or hot oil. Steamcoils or hot oil may be located vertically along the tank walls or atthe bottom of the tank. The steam coils or hot oil heat to a temperatureranging from about 100° F. up to and including 180° F. The heatingtemperature depends on solvent temperature tolerance. It has beenobserved that this type of heating facilitates the contacting of liquidsand a faster displacement due to improved viscosity of the oil.

In certain embodiments, a misting system is installed in the top of abulk storage tank. It can be installed through a “sprinkler type system”comprising misters. A plurality of misters may be installed throughoutthe top of the tank, directed downward toward the hydrocarbon containedin the tank. The misters are configured to create fine droplets ofwater, for example, as small as 5 to 15 microns. The misting system maybe installed as part of a “truss system” on the outside of the tank, inorder to support the weight of the system.

Certain embodiments of the liquid-liquid extraction system comprisepipes that emanate from the floor and spread vertically and evenlythroughout the tank. Misting heads are connected to terminal ends of thepiping and are configured to point upward, or directionally away fromthe hydrocarbon stored in the tank. The water/caustic mixture may bepumped upward through the pipes and ultimately sprayed out into the tankvia the misting heads. In this configuration, the positioning of themisting heads upward enables the water/caustic mixture to be sprayed ormisted into an upper portion of the tank, creating a fog-like headerthat then lays down over the complete surface area of the tank. Incertain embodiments, the tank will not be enclosed by a floating roof ortop-side lid. This helps to ensure that the upward spray from themisting heads is not impeded and thus the water/caustic mist can laydown evenly. When the misters are pointed downward, they can have adistinct spray patterns that might or might not overlap as thehydrocarbon level in the tank rises and falls. This can lead to unevencoverage.

When misting from the top to the bottom with a solvent mixture, varioussolvent mixtures are effective. The addition of glycerol alcohol, forexample, is useful to decrease the gravity enough to allow the solventto drop through the hydrocarbon and draw from the bottom of the tank,while extracting the naphthenates. Mixtures of water, glycerol, andethanol, isopropyl alcohol (“IPA”), methanol, acetone, or other polarwater soluble solvents are effective. Water and glycerol alone, withoutthe addition of an additional alcohol, will also be effective.

The fresh water/solvent rinse can mist for as little as 12 hours or upto 120 hours (5 days), depending upon the initial level of TAN.Generally, the higher the initial TAN, the longer the rinse will need togo. In some embodiments, the misters may be set to allow for 10% to 20%of the total capacity of hydrocarbon misted over the applicableapplication period.

In certain embodiments, a misting system is not present. In suchembodiments, the inclusion of a circulation (or sparging) system may beuseful. With a circulation system, the solvent is pre-dosed with causticor acid and introduced before a mixing valve to allow for excellentcontact of the solvent and caustic or acid with the oil. The solventdosed with caustic can initially be introduced to the crude on therun-down from the provider (e.g., a ship or barge) to the tank, or thecaustic or acid can be introduced via the circulation loop at the tank.The appropriate dosage of caustic or acid and appropriate amount(percentage) of solvent that should be used is dependent upon finalspecification requirements. A solvent mixture can be highly effective inpicking up the majority of naphthenates and asphaltenes in a singlerinse. If initial TAN or asphaltene is particularly high, then it can beadvisable to increase the percentage of solvent as the solvent can havea saturation point and/or adjust dosage of caustic (e.g., elect toreduce caustic dosage by 25% up to and including 75%).

In dealing with fuel oil, where the gravity is less than 10, the causticmay be injected into a steam header/sparging system installed on thefloor of the tank. According to such embodiments, the caustic isdispersed throughout the steam and distributed throughout the tank. Thesteam condenses back to solvent mixture and displaces itself along withthe soap at the top of the tank, where it is drawn off through a seriesof high draws. In this instance, distillation would need to occur inorder to remove portions of the water in order to keep solvent/waterratio in balance.

According to certain embodiments, an initial strip/extraction withsolvent, if dosed with caustic at full strength in order to account forall of the naphthenic acid, may be sufficient to remove the majority ofnaphthenates. However, it is possible that even still there could be asmall percentage of naphthenates or asphaltenes left behind. A second orthird wash will continue to remove the remnants of naphthenates andasphaltenes. The pH of the oil after the initial strip will have beenreduced. It is useful to continue to dose solvent with caustic to atleast extent to keep the pH of the solvent above about 11. And, ofcourse, on secondary or tertiary strip cycles, the dosage will bereduced stepwise because some of the naphthenic acid has already beenconverted into naphthenate form from prior stripping cycle(s).

Once the desired quantity of naphthenates and asphaltenes is removed,the same solvent can then be used to revert the remaining quantity ofnaphthenates back to naphthenic acid. For example, according to certainembodiments, the same solvent on a circulation loop can be dosed with anacid (strong or weak acids will work). The acid can be injected alongwith the water or solvent in the misting system or at full strengththrough the sparging system and circulation loop. The naphthenates willrevert back to a naphthenic acid, and any remaining metals will createmetal salts that are washed out with the solvents. In the acid phase, nofurther asphaltenes will be extracted. In the acid phase, there will bea reduction of basic nitrogen as well.

Again, at this stage of the process, there should only be smallquantities of naphthenates present; therefore, the dosage of acidrequired to revert the naphthenates back into naphthenic acid will beminimal For this reversion step, it is useful to dose the solventmixture to a pH of around 4. As the naphthenates are converted back, thepH of the solvent dropping out will rise. The dosed solvent shouldcontinue to circulate until the pH stabilizes. The basic nitrogen numbershould be monitored as well because it also consumes acid forneutralization. The conversion back to a naphthenic acid is notinstantaneous. Once the conversion reaction is completed, any excesssodium, potassium, or calcium will have formed a water-soluble salt andwill migrate to the solvent phase and drop out with the solvent. Oncethe soap is converted back, the stable emulsion will no longer bepresent. The previously emulsified water and solvent will now quicklybreak out along with the sodium and chlorides. The oil now will have anew lower TAN and lower % asphaltene, while being water, sodium, andchloride free. A final solvent wash with no chemistry may be required toremove residual levels of strong acid.

There are a number of ways to determine how much of the naphthenates hasbeen removed. One way is by observing the actual recovery ofnaphthenates on recovery skids or in a lab, which involves washing thehydrocarbon with solvent and then adding acid to a known amount ofsolvent and observing the naphthenic acid produced.

In certain situations, the only desired result for crude extraction isto reduce the overall level of naphthenic acid in order to create “lowTAN” crude or bunker fuel. In such situations, a single solvent wash maybe sufficient. If a secondary desire is sulfur removal, then it isrecommended to remove as many naphthenates as possible because thepresence of acids (i.e., naphthenic acid) can minimize the effectivenessof sulfur removal processing steps. Therefore, if sulfur removal isdesired, in addition to producing low-TAN crude, then follow-on solventwashes may be required.

During extraction, it is useful to continuously observe pH. If the pHbegins to drive below about 11, an emulsion can develop due tosaponification. If the pH drives lower, the soap may begin to lather. Tocounteract this, it can be useful to add strong base with the solventmixture—that will minimize lathering and increase efficiency of theextraction.

For crudes that are holding excess water or for crudes known to havedesalting difficulties, a solvent mixture wash with slightly acidicwater/solvent can often help to “pre-wash” metals and salts stabilizedin the crude that can cause desalting difficulties. For any crude, it ishelpful to always check a full slate of metals and TAN level. Incomingcrude with excessive levels of sodium, calcium, iron, magnesium, copper,or other metals will most likely be holding an excessive amount ofnaphthenate soap that developed naturally in the earth's structure. Thepresence of excessive metals is typically an indicator of naphthenatesoap and typically does not reflect in the TAN, but will generally leadto recovery of additional naphthenic acid. A high metal number is anindicator the crude will have major desalting issues.

Solvent Mixtures

The solvent mixtures referred to above and used in the embodiments ofthe extraction processes described herein may comprise water incombination with various alcohols. In bulk tankage and the premise ofcirculation and contact, ultimately, the solvent mixture must be able todrop to the bottom of the tank. Most alcohols have an API or specificgravity that would not allow for it to drop to the bottom. Thus,embodiments of the present invention use glycerol, which has a low APIand is water soluble/miscible in water. The inclusion of glycerol notonly will aid in extracting soap, it will also give the solvent mixturea low enough gravity to drop out of even heavy fuel oil mixtures.

In certain embodiments, the solvent mixture may also comprise one ormore of ethanol, acetone, IPA, or methanol, in addition to thewater/glycerol mixture. The addition of these alcohols can increaseeffectiveness of the solvent when extracting the soaps. The solventmixtures must comprise water in an amount significant enough to causealcohols to want to remain with the water phase, as opposed tosolubilizing into the hydrocarbon. Useful solvent mixtures comprisewater in an amount of at least 30% by weight.

For embodiments introducing a solvent mixture by misting, the systemshould continue to mist at 10 to 20% of the total volume of the oilvolume per day until the presence of naphthenic acid is negligible inthe recovery skids. The solvent needs to continuously have causticpresent in order to minimize or eliminate the saponification effect. Thecaustic can be dosed either neat into the oil initially on the run downto the storage tank, neat on a circulation loop, or dosed within theactual solvent mixture.

For embodiments that batch treat crude with the solvent mixture or thatintroduce the solvent mixture on a circulation loop, the system shouldprovide the solvent mixture in an amount of 10% to 40% of the volume ofoil. Increasing the volume of solvent increases contact ability,increases efficiency of break between oil and solvent, and decreases thepercentage of naphthenates absorbed. In these embodiments, for theinitial solvent wash, caustic is dosed at a level sufficient to accountfor the conversion of the desired amount of naphthenic acids to soap. Onsubsequent washes, the solvent needs to have enough caustic added inorder to bring the pH up to above 11 in order to minimize the latheringeffect of soap. The initial solvent mixture can either be added into theoil on the rundown to the storage tank or via the circulation loop.

Heating

The reaction of naphthenic acid with caustic is relatively instant andrequires no heat. The solvent absorbing the soap also occurs at ambienttemperatures. The addition of nominal levels of heat, however, can beuseful. For example, heating the oil affects its viscosity, which canallow for better contact with the solvent and the break of the solventfrom the hydrocarbon. Heating the solvent can help with washingefficiency. A nominal level of heat (e.g., about 100° F. up to andincluding 150° F.) can minimize solvent wash time. It is important,however, to be mindful of the actual boiling point of the hydrocarbon,as well as the boiling point of solvent. Glycerol, for example, has anextremely high boiling point, but ethanol and methanol do not. Ifheating temperatures applied during the process rise above respectiveboiling points of hydrocarbon or solvent materials, then a clean breakbetween the solvent and hydrocarbon may not occur. When usingcirculation loop techniques, as opposed to misting techniques (e.g., tointroduce the solvent mixture to the oil), it can be useful to enclosethe top of the storage tank (e.g., with a floating roof) so as tominimize or eliminate vapors in a head space of the tank.

Caustic and Acid Dosage

The initial dose of caustic can be calculated based on the TAN of thecrude. For example, a TAN of 5.4 is actually reporting the mg/g of KOHrequired to fully neutralize the hydrocarbon. It fundamentallytranslates to 1,000 ppm of KOH per point of TAN. Since KOH isapproximately 76% strength of NaOH, when utilizing sodium hydroxide,your actual dosage can be reduced slightly to account for the increasein strength.

On subsequent dosages, to the extent required, the caustic is dosed intothe solvent mixture at an amount sufficient to make the solvent mixturehave an elevated pH above 11. A simple lab pH test checking the originalpH of solvent mixture and slowly adding small quantities of causticuntil the pH of the known quantity of solvent reaches above 11 providesthe rate needed to set caustic pumps. It can be useful to also check anactual sample of the hydrocarbon/solvent mixture. If the oil has a“milkshake” creamy appearance and the solvent appears to have created anemulsion that is slow to break, then the pH is not high enough. In suchsituation, the solvent mixture should continue to circulate whilegradual amounts of caustic are added in order to raise the pH to adesired level that eliminates the emulsion and creamy appearance.

Determining acid dosage required to convert any remnants of soap back toa free oil soluble naphthenic acid is done through observing pH changes.The first step comprises checking the original pH of the recoveredsolvent, and then slowly adding acid to the sample while continuing toobserve pH. The appropriate acid dosage is the amount necessary to makethe pH of recovered solvent equal to about 4.5 to 5. This dosage of acidis then injected into the solvent mixture bound for the circulationloop. Converting the soap back to naphthenic acid should begin uponintroduction of the acid dosed-solvent mixture, but a completeconversion can take up to 24 hours. During circulation, it is advisableto take samples of the oil/solvent solution. Allow the sample time tosit so that the solvent mixture breaks from the oil, and check the pH ofthe solvent. As the acid reacts with the naphthenates, the solvent pHwill rise. As long as the solvent pH is below 6, there is still activeacid. If the solvent pH gets above 6, although still an acidicenvironment, it can be useful to further add a small amount of acid toexpedite the conversion. As the pH of the solvent goes up, the TAN ofthe crude and calculated weak acid will also rise due to conversion. Thebasic nitrogen will begin to lower in the crude as it reacts with strongacid.

Exemplary Liquid-liquid Extraction Process

The embodiment illustrated in FIG. 1 is configured to performliquid-liquid extraction in bulk tankage. An exemplary liquid-liquidextraction technique that can be performed using the system illustratedin FIG. 1 is described below.

Step 1: If the hydrocarbon has a low flash, the first step comprises a“light distillation” utilizing nitrogen to separate and distill off thelight ends to a light ends recovery tank. If the processing tank 10comprises a floating roof, then it should include nitrogen purge valvesfor safety. This process may also be performed in a processing tanklacking a floating roof. This initial step of separating the light endsmay also be skipped depending on the end use of the hydrocarbon (e.g.,if it were bound for market at bunker fuel). Next, the hydrocarbon isheated to a temperature about 10° F. above the desired temperature theliquid-liquid extraction will be performed at. Once the temperature hasreached this point, the nitrogen purge valve is opened and nitrogen feedis pumped into the bottom of the processing tank through the spargingsystem. The light ends that vaporize are pushed to the light endsrecovery tank and re-condensed. This first step of the process is notgenerally suited for a hydrocarbon with excessive light ends.

Step 2: The water/solvent mixture dosed with caustic (e.g., about 30-50%KOH or NaOH solution, typically 50% solution) in an amount prescribedbased on the Total Acid of the hydrocarbon (e.g., 1,000 ppm per everypoint of TAN) and injected into the misting system and/or circulationloop system (e.g., one or more circulation loops incorporated with orinto the processing tank 10, as described above) via solvent tank 20.Along the way to the misting system and/or circulation loop system, aheat exchanger heats the caustic-dosed solvent mixture. The mistingsystem and/or circulation loop system distributes the caustic-dosedsolvent mixture in the processing tank, ultimately contacting thehydrocarbon to the solvent mixture. Liquid-liquid extraction proceedsvia the reaction between the caustic and the hydrocarbon, converting thenaphthenic acid into naphthenates and utilizing polarity to extractasphaltenes. (Note: If the hydrocarbon has no light ends, this would beconsidered step 1.)

Step 3: If TAN and asphaltene removal is the only desired outcome, thenthe solvent is extracted into an extracted solvent tank 40, where theextracted solvent is dosed with acid and used to revert the naphthenatesback into naphthenic acid and adjust the asphaltenes polarity enough toexcise themselves from the solvent and float

Step 4: If the hydrocarbon requires an additional sulfur removal step,then the hydrocarbon is reacted with suitable oxidizing materials towash the sulfur out. Performing the acid wash before a suitableoxidizing reaction would mitigate the effectiveness of the oxidationstep. Further optional steps may be taken for spent water recycling andnaphthenic acid recovery.

It should be appreciated that the systems and processes described hereinare advantageously useful to extract a number of undesirableconstituents from a hydrocarbon stock. Notably, that includesnaphthenates/naphthenic acids, metals, and salts, but the processesextract, more generally, constituents in the hydrocarbon that are polar.The pH of the solvent in the caustic phase allows hydrocarbons that haveany level of polarity to migrate to the solvent to be extractable withnaphthenic acid. Additionally, the processes and systems describedherein can isolate and extract the following array of undesirablematerials: asphaltenes, phenols, metals, hydrogen, oxygen, nitrogen,hydrogen sulfide and mercaptans, chlorides, and waxes, among others.

Asphaltenes tend to migrate to high pH solvent. They becomemiscible/soluble in the alcohol solvent. Asphaltenes have a polar tail,which is why they often cause emulsion issues at a desalter especiallyin conjunction with naphthenic acids. The high pH solvent is conducivefor the asphaltenes of all carbon chain lengths to migrate to thesolvent. Migration occurs in the high pH environment, where the polarityof the solvent and the non-polarity of the oil is at its closest.

Phenols are not typically prevalent in crude oil; however, they doappear on occasion, deriving from specialty chemicals being placeddownhole or slop oil or re-run being reintroduced into crude forrefining along with some naturally occurring. Phenols are soluble inalcohol and will migrate to the solvent during the extraction processesdescribed herein.

Most metals in the caustic phase will either be present in the form of asalt or a naphthenate and tend to migrate to the solvent phase. Metalsare recovered in the acid phase of the extraction process as anyremaining naphthenates not extracted in the caustic phase are convertedback to a naphthenic acid, and the metal subsequently forms a salt thatis polar and migrates to the solvent.

It has been stated that the processes and systems described hereinextract salts and acid. Accordingly, inorganic chlorides will reflect ineither a salt or an acid. They are predominately highly water solubleand thus extractable in the water-solvent mixture. Organic chlorides,however, tend to migrate to the oil phase. Industry desalters arerelatively ineffective at removing them. Organic chlorides are man-madeand should not ideally exist in crude, but nevertheless are often foundin crude, in low grade fuel oil, and in bunker fuel. The processesdescribed herein have an extraction effect on some of the commonly foundorganic chlorides, such as chloroform or variants of vinyl chloride,either due to a reaction with caustic forming a water, or alcoholsoluble salt, or solubility with ethanol or alcohol in general.

All refiners, regardless of their crude slate, must deal with thecomponents of crude that cause a variety of downstream issues. Forexample, corrosion and fouling throughout the refinery are a largeconcern. Salts, nitrogen, oxygen, metals, naphthenic acid, strong acids,CO₂ and asphaltenes are major causes of both. By extracting the majorityof these constituents using the processes described herein willmeaningfully reduce fouling and corrosion throughout the refinery.

For example, many units in a refinery function with a catalyst reaction.Metals, nitrogen, and oxygen are primary poisons to all these catalysts.Refiners also have ancillary units throughout the refinery to deal withremoval of H₂S, mercaptans, and CO₂ using amines, caustic, oxidation, orsome type of catalyst. Naphthenic acids, naphthalenes, metals,asphaltenes all effect the final product quality specifications and,more specifically, test results that indicate emissions issues. Theextraction of these undesirable materials in advance of refineryprocessing (1) reduces workload and degradation on downstream unitsdesigned to deal with such materials, (2) yields downstream productionof cleaner products, and (3) reduces harmful environmental emissionsattributable to the various downstream refining processes.

While crude has been mentioned throughout this description, the systemsand processes described herein are not limited to crude. The embodimentsdescribed herein are effective on hydrocarbon inputs, products, and feedstreams generally, if the API gravity of the stream is higher than thatof the solvent mixture, which can range from a 5 to a 15 API gravitydepending upon the ratio of glycerol in the solvent mixture. Generally,the API of the solvent mixture may fall within the range of 7 up to andincluding 9, which is typically advantageous for dealing with heavycrudes. The solvent mixture is effective at a higher API, however, wherethe water/alcohol-to-glycerol ratio is higher. This is less common butcan present itself with residue streams and clarified slurry oil, whichcan often have an API lower than the solvent mixture. In thoseinstances, it may be advantageous to add a cutter to lift gravity of theproduct stream to increase effectiveness of the extraction process.

As mentioned, the systems and processes described herein providepotential downstream co-product/by-product benefits at downstreamprocessing plants. For example, considering a fuel oil blend stock witha TAN over 100. A titration revealed the acid in the stream was a weakacid. Using the liquid-liquid extraction processes described herein, theacid was easily extracted. It is doubtful that such acid was anaphthenic fatty acid, which has been discussed above. Rather, it wasmore likely derived from an entrainment of some form of weak acid beingused as a catalyst in a co-product stream. Pyrolysis gas oil streams arecommon co-products stemming from chemical plants being blended to bunkeror fuel oil. They predominately have great properties but can have a fewspecifications due to entrainment or reaction that are unwanted. Usingthe embodiments described herein on non-crude streams have also proveneffective.

The embodiments described herein provide further positive advantages fortank cleaning, rerun production and API separator sludge production. Theprocesses described have a profound impact on future production andbuild-up of sludge throughout the refinery. Crude tanks, for example,develop a large heel of sludge that is primarily a combination ofemulsified water, hydrocarbon with polarity issues, and metals. Theembodiments of the present invention extract water, polar hydrocarbons,and metals, and thus will inherently minimize future build-up of sludgewithin a crude tank. Crude tank sludge is designated as hazardous wastewith cradle-to-grave disposal implications pursuant to federal and stateregulations. Most countries in the world also regulate crude tankbottoms with hazardous waste disposal regulations. Crude tank sludge isa major yearly source of reportable solid waste production at a refineryor terminal, and implementation of the systems and processes describedherein can markedly reduce such waste.

Another positive advantage is the ability to rerun sludge to also helpprevent build-up in equipment. A way to do this, for example, is to addand blend a caustic-dosed solvent mixture with the sludge to convert thesludge to reduce its viscosity and make it a pumpable material. Once itis pumpable, the treated sludge is transferred back into a processingtank to undergo the extraction processes described above. Rerunningsludge in this manner can help reduce solid waste disposal.

Product tanks similarly develop natural build-up and can, over time,develop a heel of sludge due to metals and incompatible portions of theproduct that tend to flocculate out. As with crude tanks, extractingmetals and incompatible portions of crude will minimize the buildup ofsludge in such product tanks. Most product tanks are designatedhazardous waste with cradle-to-grave issues of their own. Product tankdisposal is a major source of reportable solid waste production within arefinery on a yearly basis, and implementation of the systems andprocesses described herein can markedly reduce such waste

A type of sludge of particular interest is API separator sludge, whichis an emulsion, a tar like substance of heavy oils, metals, and water.It is a registered hazardous waste. The main source of API separatorsludge is desalter water oil under carry. The embodiments of the presentinvention enable a refinery to bypass desalter processing, thereforeseverely minimizing the production of API separator sludge. API skim oilis the oil that instead of sinking and forming a sludge remains floatingand is skimmed and re-routed to re-run or slop oil tanks. The majorsource of skim oil is a desalter as well. The skim oil system is open tothe atmosphere and is a source of reportable emissions for a refinery.The elimination of desalters and desalter processing, as provided for bythe present invention, can severely reduce the skim oil production.

Rerun or slop oil is the agglomeration of all oil that does notcompletely make it through the refining process and refiners mustattempt to re-process. It must be fed slowly as its metal content, watercontent, cleanliness and incompatible portions of crude are a majorsource of upsets and subsequent products going off-spec thus creatingadditional re-run. Slop oil emulsions are designated hazardous waste.The EPA does not define the specific bounds for slop oil, so mostrefiners must consider the entire tank hazardous waste if they elect todispose. Disposal is an expensive and reportable event. Most refinersseek to avoid disposal and opt instead to attempt to re-process, oftenwith detrimental effects. Extracting metals, naphthenic acids, andincompatible portions of crude while the crude is in bulktankage—according to the processes described herein—significantlyincreases desalter efficiency, which can severely mitigate theproduction of rerun or slop oil that refiners are effectively left toreprocess.

In addition to reducing waste, prolonging refinery equipment, andincreasing efficiency and processing output, the inventive systems andprocesses described herein have multiple positive environmental impacts.The embodiments described herein have a positive and cumulative effecton fuel gas and natural gas consumption at refinery, quantity ofwastewater and quality of water outfall at a refinery, actual freshwater consumed at a refinery, total carbon footprint and emissions atrefinery, reduction of power consumed at pumps and compressors atrefinery, improvement of carbon footprint and total emissions of allproducts produced at a refinery, as well as reduction of solid wastebound for disposal at a refinery. A total carbon footprint of a refinerynot only accounts for power consumption, fuel consumption, waterconsumption, and emissions, but also encompasses incoming and outgoingmaterials and products for consumption within the refinery and materialexiting the refinery for disposal or recycling. The systems and methodsdescribed herein minimize both incoming products and outgoing disposaland recycling operations—thus minimizing the complete carbon footprintof a refinery.

Examples of incoming reduction of footprint are delivery via vehicle ofincoming specialty chemicals and commodity chemicals, such as scrubbingamines and cartridge filters, to be used throughout the facility tofilter metals and incompatible particulates. Examples of outgoingreductions of the overall carbon footprint are solid waste productionfrom tankage and API separators that include both the transportation andthe subsequent incineration for little to no productive use. There willalso be a reduction in spent amines that must be sent out for disposalor recycling. In sum, the cumulative benefits are measurable andaccountable on water, air, and solid waste.

1. A liquid-liquid extraction method comprising: determining a totalacid number of hydrocarbon stored in a bulk tankage unit; dosing asolvent feed with a caustic solution at 1,000 ppm of the causticsolution per point of the total acid number of hydrocarbon; circulatingthe solvent feed dosed with the caustic solution into the bulk tankageunit via one or more circulation loops connected to the bulk tankageunit, wherein circulating causes the solvent feed dosed with causticsolution to contact the hydrocarbon; extracting metal soaps from thehydrocarbon formed in the bulk tankage unit; decanting the solventmixture from the hydrocarbon in the bulk tankage unit; and transportingthe decanted solvent mixture from the bulk tankage unit to a solventrecovery tank separate from the bulk tankage unit, wherein solubleconstituents of the solvent mixture are separated from the decantedsolvent mixture and the solvent mixture is recycled for reuse.
 2. Theliquid-liquid extraction method of claim 1, wherein the decanted solventmixture transported from the bulk tankage unit to the solvent recoverytank comprises naphthenates and asphaltenes from the hydrocarbon storedin the bulk tankage unit.
 3. The liquid-liquid extraction method ofclaim 2, wherein the decanted solvent mixture transported from the bulktankage unit to the solvent recovery tank further comprises salts,metals, chlorides, hydrogen sulfide, mercaptans, phenols, and polycyclicaromatic hydrocarbons from the hydrocarbon stored in the bulk tankageunit.
 4. The liquid-liquid extraction method of claim 1, wherein thesolvent feed comprises water, one or more alcohols, and glycerin.
 5. Theliquid-liquid extraction method of claim 4, wherein the solvent feedcomprises ethanol.
 6. The liquid-liquid extraction method of claim 4,wherein the solvent feed comprises 30-50 wt.-% alcohol(s), 20-40 wt.-%water, and 20-40 wt.-% glycerin.
 7. The liquid-liquid extraction methodof claim 1, wherein circulating the solvent feed dosed with causticsolution into the bulk tankage unit comprises circulating the solventfeed in a ratio amount of at least 10:50 by mass compared to the amountof the hydrocarbon in the bulk tankage unit.
 8. The liquid-liquidextraction method of claim 1, wherein circulating the solvent feed dosedwith caustic solution into the bulk tankage unit causes the solvent feedto contact the hydrocarbon for at least six hours.
 9. The liquid-liquidextraction method of claim 1, wherein circulating the solvent feed dosedwith caustic solution into the bulk tankage unit causes the solvent feedto contact the hydrocarbon for a period until the total acid number ofthe hydrocarbon is non-detectable.
 10. The liquid-liquid extractionmethod of claim 1, further comprising, after transporting the decantedsolvent mixture from the bulk tankage unit to a solvent recovery tankseparate from the bulk tankage unit, acidizing the decanted solventmixture, recovering asphaltene and naphthenic acid from the decantedsolvent mixture, and recycling the solvent mixture through reverseosmosis skids.
 11. The liquid-liquid extraction method of claim 10,wherein recycling the solvent mixture through the reverse osmosis skidscomprises capturing phenols and polycyclic aromatic hydrocarbons. 12.The method of claim 11, further comprising: sending the captured phenolsand polycyclic aromatic hydrocarbons to thermal desorption units;producing steam at the thermal desorption units; and using the steam inone or more heating units integrated with the bulk tankage unit.
 13. Theliquid-liquid extraction method of claim 1, wherein circulating thesolvent feed dosed with caustic solution into the bulk tankage unitcomprises using a heat exchanger on the one or more circulation loops toheat the solvent feed dosed with caustic to a temperature ranging fromat least 100° F. up to and including 200° F.
 14. The liquid-liquidextraction method of claim 1, wherein dosing the solvent feed with thecaustic solution occurs concurrently as the solvent feed is circulatedinto the bulk tankage unit.
 15. The liquid-liquid extraction method ofclaim 1, further comprising additionally dosing the solvent feed with anacid and circulating the solvent dosed with acid into the bulk tankageunit to cause the acid to contact the hydrocarbon.
 16. A bulk tankageliquid-liquid extraction system comprising: a bulk storage tank thathouses static hydrocarbon; a solvent feed tank separate from the bulkstorage tank; a circulation loop connecting the solvent feed tank to thebulk storage tank, configured to circulate a solvent mixture into thebulk storage tank so as to contact the solvent mixture with the statichydrocarbon in the bulk storage tank; and a sump unit located on thebottom half of the bulk storage tank, the sump unit configured to pumpthe solvent mixture out of the bulk storage tank after completion of aliquid-liquid extraction reaction between the solvent mixture and thestatic hydrocarbon.
 17. The system of claim 16, further comprising aheating unit installed at the bottom of the bulk storage tank, along oneor more sidewalls of the bulk storage tank, or both, wherein the heatingunit is a hot oil or steam coil system configured to heat the statichydrocarbon during the liquid-liquid extraction reaction completedinside the bulk storage tank.
 18. The system of claim 16, furthercomprising a heat exchanger attached to the circulation loop, whereinthe heat exchanger is configured to heat the solvent mixture duringtransport from the solvent feed tank to the bulk storage tank.
 19. Thesystem of claim 16, further comprising a sparging unit at the bottom ofthe bulk storage tank, wherein the sparging unit comprises a pluralityof vortexing nozzles configured to blend the static hydrocarbon and thesolvent mixture after the solvent mixture is circulating into the bulkstorage tank.
 20. The system of claim 16, wherein the sump unit isconfigured to pump naphthenates, asphaltenes, hydrogen sulfide,mercaptans, and phenols out of the bulk storage tank with the solventmixture after the completion of the liquid-liquid extraction reaction.21. The system of claim 16, further comprising a plurality of electricalprobes connected to a roof on the bulk storage tank, wherein theplurality of electrical probes deliver electrical current into thestatic hydrocarbon inside the bulk storage tank.